PURPOSE

This campaign bulletin instructs dealers to inspect and, if necessary, replace the drive belt auto tensioner with a countermeasure part.

BACKGROUND

Due to repetition of high load operations, the flange of the drive belt automatic tensioner may crack, causing detachment of the drive belt. If the drive belt detaches, the alternator will not charge the battery, causing an engine stall and/or the power steering assist will be disabled, increasing the risk of a crash.

AFFECTED VEHICLES

Certain 2009 - 2012 Lancer built March 20, 2008 - November 17, 2011
Certain 2010 - 2012 Lancer Sportback built June 17, 2009 - November 15, 2011
Certain 2008 - 2012 Outlander built June 25, 2008 - November 16, 2011
Certain 2011 - 2012 Outlander Sport/RVR built August 26, 2010 - December 15, 2011

CUSTOMER NOTIFICATION

Letters will be sent to all owners of affected vehicles requesting them to bring their vehicle to a local
Authorized Mitsubishi dealer to have their vehicle remedied. Copies of the customer notification letters
appear at the end of this bulletin.

REQUIRED OPERATIONS

Before starting this campaign procedure, CHECK THE WARRANTY SUPERSCREEN to verify if the
vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

Inspect the front bumper and fenders for presence of any damages or scratches. If damages or scratches are found, notify the customer before proceeding.

Vehicle and engine components may be hot.

Panel edges inside the engine compartment may be sharp.

AUTO TENSIONER INSPECTION

	Remove the radiator condenser tank mounting bolt, and move the radiator condenser tank to a place where it does not interfere with the removal and installation of the drive belt.
	Inspect the auto tensioner flange with a mirror and a flashlight to check whether the flange is before (concave type flange) or after (straight type flange) the countermeasure. NOTE: It may be easier to check if you move a mirror closer to the auto tensioner along the drive belt

	Placing the mirror closer to the auto tensioner along the drive belt.

	Check the auto tensioner and note the flange shape. If the flange is straight, as illustrated in figures A and B, leave as is and go to step 4. If the flange is concave, as illustrated in figure C, proceed to Auto Tensioner Removal process.
	Reinstall the radiator condenser tank. Repair is now complete.

AUTO TENSIONER REMOVAL

If the flange is concave, proceed with the repair.

1. Turn the steering wheel fully to the right.
2. Raise the vehicle. Remove the circled undercover(s).
1. Lancer and Lancer Sportback

2. Outlander

3. Outlander Sport/RVR

Make a mark on the drive belt, with chalk, to indicate the rotation direction before removing the drive belt. NOTE: As the drive belt will be reused, marking the rotation direction will help you reinstall the drive belt in the correct orientation.

Release the auto tensioner tension from the top of the engine compartment. DO NOT perform the work from underneath the vehicle because work posture becomes unstable and there is a risk of tool detachment.

For a box-end wrench combined with the special tool, select the most appropriate one so that the work can be performed at the easiest angle.

As the tension of the auto tensioner is high, make sure to set the hex wrench to each hexagonal socket to prevent the tool from being detached.

4. Use a box-end-wrench [45 degree offset long box end wrench (5/8 x 11/16 inches) recommended], on the pulley bolt of the auto tensioner. Rotate the auto tensioner counterclockwise, and insert a L-shaped hexagon wrench into the auto tensioner hole to to fix the auto tensioner.

5. Remove the drive belt.
6. Remove the (2) idler pulleys and then remove the auto tensioner.

INSTALLATION PROCEDURE

New flange bolts (MW400221 [contains 2 pieces]) must be used with the new auto tensioner.

1. Install the new auto tensioner, and tighten to 16 ± 3 ft-Ib (22 ± 4 Nm).
2. Install the idler pulleys. Tightening torque: 35 ± 5 ft-lb (48 ± 7 Nm)
3. Installation of the Drive Belt.
1. Refer to the applicable service manuals for the belt routing diagram.
2. Install the drive belt in the correct rotating direction of the drive belt as indicated in AUTO TENSIONER REMOVAL procedure.
3. Set a box-end wrench (angle of 45 degrees box-end wrench [5/8 x 11/16 inches] recommended) on the pulley bolt of the auto tensioner.
   Rotate the auto tensioner in a counterclockwise direction and remove the pin that came with the new auto tensioner.

4. Apply tension to the drive belt by slowly rotating the auto tensioner in a clockwise direction.

After the drive belt is reinstalled, rotate the crankshaft in a clockwise direction. Using a mirror, make sure that the auto tensioner indicator mark is located within the “A” range, shown in this figure. NOTE: When the auto tensioner indicator mark is located out of the range of “A in the following image”, the belt needs to be replaced because it is extended. CAUTION: Verify the drive belt's notched side is mated correctly to the notched pulleys and the drive belt's flat side is centered on the flat pulleys. (Shown in figure on page 9)

6. Reinstall the radiator condenser tank.
7. Start the engine to make sure that there is no abnormal noise.
8. Reinstall the engine compartment side cover (RH) and front undercover (if applicable).

RECALL CAMPAIGN CLAIM INFORMATION

Enter all claims as claim type 'C' - Recall/Campaign Claims

Please follow the campaign instructions when entering each claim. See the example below.

Certain 2008-2012 Outlander, 2011-2012 Outlander Sport, 2009-2012 Lancer and 2010-2012 Lancer Sportback models only.

Claim Header Section: Drive Belt Auto Tensioner

After entering the required customer data, vehicle information, select the applicable campaign operation number and the one replacement scenario that was actually performed. Then, by hitting the “Save and Continue” button, the system will automatically fill-in several other fields.

LABOR AND PARTS:

There are up to 4 possible repair scenarios for this campaign - follow the charts provided to select the appropriate labor operation that applies to the vehicle.

There are multiple repair scenarios for this campaign.

Outlander

Lancer and Lancer Sportback

Outlander Sport/RVR

RENTAL CARS:

If there is a need to provide the owner with a rental car, claim the applicable charges in this section of the recall claim on the lower portion of the labor entry screen.

NOTE: Rental Cars applicable in the US and Puerto Rico only.

Copyright 2018, Mitsubishi Motors North America, Inc.